Diffuser Bump Vane Profile for ESP Efficiency
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Solution Overview
Problem
Modern electric submersible pumps (ESPs) in oil and gas environments face inefficiencies due to turbulent fluid flow caused by separation from diffuser vanes, which decreases pump efficiency and head, as there is insufficient space for long diffusers.
Innovation Solution
The design incorporates a frustoconical diffuser with a bump on its vanes, increasing the length of the low-pressure surface to promote laminar fluid flow without increasing the axial length, and similar bumps on impeller blades to reduce fluid separation and turbidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the axial length of the diffuser is increased to reduce fluid separation, then pump efficiency is improved, but the device cannot be installed in constrained spaces
Solution Approach 1:
The patent applies dimensionality change by adding a bump protrusion in the radial direction (width dimension) rather than extending the diffuser axially. This allows the low-pressure surface length to be increased without increasing the axial length, resolving the contradiction between pump efficiency and space constraints.
Solution Approach 2:
The bump is strategically positioned on the low-pressure surface of the diffuser vane to locally extend the flow path. This localized modification increases the effective length where fluid separation occurs without requiring a global increase in axial length, thereby improving efficiency while maintaining compact dimensions.
2Reliability
If the diffuser vane length is increased to maintain laminar flow, then fluid separation is reduced, but the device complexity increases
Solution Approach 1:
The diffuser vane is segmented into distinct functional regions: a bump protrusion on the low-pressure surface and a corresponding recess on the high-pressure surface. This segmentation allows the flow path to be extended in a controlled manner while maintaining structural integrity and simplifying manufacturing compared to a fully custom-shaped vane.
Solution Approach 2:
The bump and recess configuration creates an asymmetric flow path that favors laminar flow development. The asymmetric geometry is specifically designed to extend the low-pressure surface length while maintaining the high-pressure surface geometry, thereby promoting laminar flow without requiring complete redesign of the vane structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces fluid separation and turbidity, enhancing pump efficiency and pumping head by maintaining laminar flow and allowing for increased fluid handling capacity in constrained spaces.
Implementation Method 1
The low pressure surface has a length greater than the length of the high pressure surface so that fluid flowing along the low pressure surface is substantially laminar
Data Source
AI summary
An electric submersible pump (ESP) assembly increases pump efficiency and pump head with a diffuser that includes a diffuser vane having a low pressure surface with a length greater than a length of a high pressure surface of the vane. The diffuser vane includes a leading edge at a downstream end of the vane and a trailing edge at an upstream end of the vane. The curved high pressure surface extends between the leading edge and the trailing edge. The curved low pressure surface extends between the leading edge and the trailing edge opposite the high pressure surface. The low pressure surface has a bump formed thereon to increase the length of the low pressure surface so that fluid flowing along the low pressure surface is substantially laminar, thereby increasing pump efficiency and pump head.